U.S. patent number 10,595,951 [Application Number 15/665,789] was granted by the patent office on 2020-03-24 for force sensor for surgical devices.
This patent grant is currently assigned to Covidien LP. The grantee listed for this patent is Covidien LP. Invention is credited to Patrick Mozdzierz, Anthony Sgroi, David Valentine.
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United States Patent |
10,595,951 |
Mozdzierz , et al. |
March 24, 2020 |
Force sensor for surgical devices
Abstract
The present disclosure relates to force sensors and force sensor
substrates for use with surgical devices.
Inventors: |
Mozdzierz; Patrick
(Glastonbury, CT), Sgroi; Anthony (Wallingford, CT),
Valentine; David (East Hampton, CT) |
Applicant: |
Name |
City |
State |
Country |
Type |
Covidien LP |
Mansfield |
MA |
US |
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Assignee: |
Covidien LP (Mansfield,
MA)
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Family
ID: |
59745706 |
Appl.
No.: |
15/665,789 |
Filed: |
August 1, 2017 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20180042689 A1 |
Feb 15, 2018 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62375012 |
Aug 15, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01L
1/2243 (20130101); G01L 5/0028 (20130101); A61B
34/25 (20160201); G01L 1/2268 (20130101); A61B
34/77 (20160201); A61B 17/1155 (20130101); A61B
34/76 (20160201); A61B 2017/0046 (20130101); A61B
2017/00473 (20130101); A61B 2034/2061 (20160201); A61B
2017/00017 (20130101); A61B 2017/00398 (20130101); A61B
2090/064 (20160201) |
Current International
Class: |
G01L
1/00 (20060101); A61B 34/00 (20160101); G01L
5/00 (20060101); G01L 1/22 (20060101); A61B
17/115 (20060101); A61B 90/00 (20160101); A61B
17/00 (20060101); A61B 34/20 (20160101) |
Field of
Search: |
;73/862.627 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
European Search Report dated Dec. 22, 2017 issued in corresponding
EP Application No. 17186269.1. cited by applicant.
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Primary Examiner: Noori; Max H
Attorney, Agent or Firm: Carter, DeLuca & Farrell
LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of and priority to U.S.
Provisional Patent Application No. 62/375,012 filed Aug. 15, 2016,
the entire disclosure of which is incorporated by reference herein.
Claims
What is claimed is:
1. An adapter assembly for selectively interconnecting an end
effector configured to perform a function and a handle assembly
configured to actuate the end effector, the adapter assembly
comprising: an outer sleeve; a connector housing secured to a
distal end of the outer sleeve; a trocar connection housing
disposed within the outer sleeve; and a force sensor disposed
between the connector housing and the trocar connection housing,
the force sensor including a substrate including a proximal surface
having a proximal load contact area and a distal surface having at
least one distal load contact area and a sensing area, the distal
surface being planar and having at least one groove defined therein
separating the at least one distal load contact area from the
sensing area.
2. The adapter assembly according to claim 1, wherein the trocar
connection housing includes a distal surface that interfaces with
and loads the proximal surface of the force sensor at the proximal
load contact area, and the connector housing includes a proximal
surface that interfaces with and loads the distal surface of the
force sensor at the at least one distal load contact area.
3. The adapter assembly according to claim 1, further including a
trocar assembly extending through a central aperture of the force
sensor and a central aperture of the trocar connection housing.
4. The adapter assembly according to claim 3, wherein the proximal
load contact area of the force sensor is disposed adjacent to the
central aperture of the force sensor.
5. The adapter assembly according to claim 1, wherein the at least
one distal load contact area of the force sensor includes four
distal load contact areas disposed at corners of the substrate.
6. The adapter assembly according to claim 1, wherein the sensing
area of the force sensor is a flat continuous surface including
sensing elements dispose thereon, the sensing area is free from
direct contact with the at least one distal load contacting area
via the at least one groove.
7. The adapter assembly according to claim 6, wherein the sensing
elements are strain gauges.
8. The adapter assembly according to claim 1, wherein a coating is
disposed over the sensing area of the force sensor and terminates
at the at least one groove.
9. The adapter assembly according to claim 1, wherein the force
sensor includes a groove defined in the sensing area.
10. The adapter assembly according to claim 9, further including a
flex cable coupled to the groove of the sensing area via solder
joints.
Description
TECHNICAL FIELD
The present disclosure relates generally to surgical devices. More
particularly, the present disclosure relates to force sensors for
powered surgical devices.
BACKGROUND
Force sensors are known, and there are multiple methods of
fabricating these types of sensors. In one method, sensors utilize
bonded strain gauges adhered to a flexing substrate within a load
path. For example, a simply supported steel beam that is used
integral to a load path can have a strain gauge mounted on the
beam. The strain gauge is incorporated in a Wheatstone Bridge
Circuit configuration and includes an excitation voltage. The
circuit is designed to be at balance before deflection (i.e., no
load) and the circuit will have a resistance at zero load. During
loading, the beam will deflect and the strain gauge will produce a
resistance change. This resistance change is a signal that can be
converted into a force value imposed on the beam using a signal
conditioner. Depending on the type of configuration (e.g., a
quarter bridge, a half bridge, a full bridge), the signal will vary
and require calibration to obtain the actual force imposed.
Some strain gauges incorporate a thin plastic film with a bonded
NiCr (nickel-chromium or nichrome) wire path embedded on the film.
When the film is bonded to the beam and the beam is deflected, the
NiCr wire will also be subjected to bending causing a deformation
of the wire. The deformation of the wire will cause the above
mentioned change in electrical resistance.
The flexing substrate must be configured to elastically deform in
an elastic region. In the event that the substrate is subjected to
permanent deformation, the sensing wire of the strain gauge will be
constrained in the deformed state. This will result in inaccurate
subsequent readings of the sensor.
Solder connections are typically utilized in a strain gauge
circuit, with the wire path of the strain gauge terminating at a
pair of solder pads. Other connections are also used, such as laser
welding, mechanical forcing of wires to the contact pads, etc.
The solder connections are subject to possible failures if the
connections are made in areas of high strain. Such a strain can
cause high levels of deformation causing the solder connections to
fatigue. Depending on the level of strain, this fatigue can cause
failure of the solder pad resulting in a loss of electrical signal
rendering the sensor unusable.
If alternate sensors are used, e.g., those fabricated using vapor
deposition of brittle materials, this phenomena can become more
problematic. Sensor fabricated using vapor deposition include
depositing several layers of media to create the sensor. Typically,
the first layer consists of a thin layer of glass deposited along a
surface that will incorporate the sensing wire. The sensing wire is
first deposited along the substrate as a full NiCr covering. A
laser then etches away the NiCr until the desired wire path is
created having a plurality of solder pads forming a sensing element
as described above with respect to the bonded strain gauge.
Finally, a covering layer is used to prevent moisture ingress
preventing shorts of the wire trace. The covering layer may be a
cured epoxy or an RTV sealant (e.g., room temperature vulcanization
silicone), or a vapor deposited glass with a region of glass etched
away to gain access to the solder pads. This allows for the
soldering of the wires or a flex cable to the sensor.
The configurations described above suffer from problems. One
problem is the ability to load the substrate in an instrument. When
utilizing glass along the substrate, the glass can crack when
loaded. Another problem is premature failing due to large strains
on the solder pads.
SUMMARY
In one aspect of the present disclosure, a force sensor substrate
includes a proximal surface including a proximal load contact area,
and a distal surface including at least one distal load contact
area and a sensing area. The distal surface is planar and has at
least one groove defined therein separating the at least one distal
load contact area from the sensing area.
According to another aspect of the present disclosure, a force
sensor substrate includes a proximal surface including a proximal
load contact area and a distal surface including a distal load
contact area and a sensing area. The distal surface is planar and
has at least one groove defined in the sensing area.
Embodiments can include one or more of the following
advantages:
The force sensors and substrates thereof may be configured to
withstand large loading forces without disrupting the surface
containing the sensing electronics (e.g., sensing elements or
strain gauges, and their associated components).
The force sensors and substrates thereof may be configured to
prevent tear propagation of protective conformal coatings and/or
layers of sensing elements disposed thereon, and/or prevent surface
micro-strain from damaging solder welds.
The force sensors and substrates thereof may be configured to
withstand environmental stresses associated with autowashing and/or
autoclaving, thereby rendering the force sensors more durable for
reuse.
Other aspects, features, and advantages will be apparent from the
description, drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the present disclosure are described herein
below with reference to the drawings, which are incorporated in and
constitute a part of this specification, wherein:
FIG. 1 is a perspective view of a surgical device in accordance
with an embodiment of the present disclosure;
FIG. 2 is a perspective view of an adapter assembly of the surgical
device of FIG. 1;
FIGS. 3A and 3B are perspective views of a distal end portion of
the adapter assembly of FIGS. 1 and 2, with an outer sleeve of the
adapter assembly removed;
FIG. 3C is an enlarged perspective view of a part of the distal end
portion of FIGS. 3A and 3B;
FIG. 4A is a perspective view of a trocar connection housing
disposed in the distal end portion of the adapter assembly of FIGS.
3A-3C;
FIGS. 4B and 4C are perspective views of proximal and distal
surfaces, respectively, of a substrate of a force sensor disposed
in the distal end portion of the adapter assembly of FIGS.
3A-3C;
FIG. 5 is a perspective view of the substrate of the force sensor
of FIGS. 3A-3C, 4B, and 4C in accordance with an embodiment of the
present disclosure;
FIG. 6A is a perspective view of a substrate of a force sensor in
accordance with another embodiment of the present disclosure;
FIG. 6B is a close-up view of a groove defined in the substrate of
FIG. 6A; and
FIGS. 7A and 7B are perspective views of the substrate of FIGS. 6A
and 6B, including a flex cable and a substrate ground tab.
DETAILED DESCRIPTION
Embodiments of the present disclosure are now described in detail
with reference to the drawings in which like reference numerals
designate identical or corresponding elements in each of the
several views. Throughout this description, the term "proximal"
refers to a portion of a device, or component thereof, that is
closer to a hand of a user, and the term "distal" refers to a
portion of the device, or component thereof, that is farther from
the hand of the user.
Turning now to FIG. 1, a surgical device 1, in accordance with an
embodiment of the present disclosure, is in the form of a powered
handheld electromechanical instrument, and includes a powered
handle assembly 10, an adapter assembly 20, and a tool assembly or
end effector 30 including a loading unit 32 having a plurality of
staples (not shown) disposed therein and an anvil assembly 34
including an anvil head 34a and an anvil rod 34b. The powered
handle assembly 10 is configured for selective connection with the
adapter assembly 20 and, in turn, the adapter assembly 20 is
configured for selective connection with the end effector 30.
While described and shown as including adapter assembly 20 and end
effector 30, it should be understood that a variety of different
adapter assemblies and end effectors may be utilized in the
surgical device of the present disclosure. For a detailed
description of the structure and function of exemplary surgical
devices, reference may be made to commonly owned U.S. patent
application Ser. No. 14/991,157 ("the '157 application"), filed on
Jan. 8, 2016, and Ser. No. 15/096,399 ("the '399 application"),
filed on Apr. 12, 2016, the entire contents of each of which are
incorporated herein by reference.
With continued reference to FIG. 1, the handle assembly 10 includes
a handle housing 12 housing a power-pack (not shown) configured to
power and control various operations of the surgical device 1, and
a plurality of actuators 14 (e.g., finger-actuated control buttons,
knobs, toggles, slides, interfaces, and the like) for activating
various functions of the surgical device 1. For a detailed
description of an exemplary handle assembly, reference may be made
to the '399 application, the entire contents of which was
previously incorporated herein by reference.
Referring now to FIG. 2, in conjunction with FIG. 1, the adapter
assembly 20 includes a proximal portion 20a configured for operable
connection to the handle assembly 10 (FIG. 1) and a distal portion
20b configured for operable connection to the end effector 30 (FIG.
1). The adapter assembly 20 includes an outer sleeve 22, and a
connector housing 24 secured to a distal end of the outer sleeve
22. The connector housing 24 is configured to releasably secure an
end effector, e.g., the end effector 30 (FIG. 1), to the adapter
assembly 20.
The adapter assembly 20 will only further be described to the
extent necessary to fully disclose the aspects of the present
disclosure. For detailed description of an exemplary adapter
assembly, reference may be made to the '157 application, the entire
contents of which was previously incorporated herein by
reference.
With reference now to FIGS. 3A-3C, the adapter assembly 20 further
includes a trocar assembly 26 that extends through a central
aperture 101 (FIG. 4B) of a force sensor 100 and a central aperture
29 (FIG. 4A) of a trocar connection housing 28. The trocar
connection housing 28 releasably secures the trocar assembly 26
relative to the outer sleeve 22 (FIG. 2) of the adapter assembly
20. For a detailed description of an exemplary trocar connection
housing, reference may be made to U.S. patent application Ser. No.
14/865,602 ("the '602 application"), filed on Sep. 25, 2015, the
entire contents of which are incorporated herein by reference.
The force sensor 100 is disposed between the trocar connection
housing 28 and the connector housing 24 of the adapter assembly 20,
and is configured to measure forces along a load path. As shown in
FIGS. 4A and 4B, in conjunction with FIG. 3C, the trocar connection
housing 28 (FIG. 4A) includes a distal surface 28a which interfaces
with, and loads a proximal surface 102a (FIG. 4B) of a body or
substrate 102 of the force sensor 100 at proximal load contact
areas "Cp". As shown in FIG. 4C, in conjunction with FIG. 3C, a
proximal surface 24a (FIG. 3C) of the connector housing 24 defines
a contact surface which loads a distal surface 102b of the
substrate 102 of the force sensor 100 at distal load contact areas
"Cd" (FIG. 4C). Thus, for example, as the anvil assembly 34 (FIG.
1) is approximated towards the loading unit 32 of the end effector
30 during clamping and/or stapling of tissue, the anvil head 34a
applies uniform pressure in the direction of arrow "A" (FIG. 3A)
against the distal end 24b of the connector housing 24 which, in
turn, is transmitted to the distal load contact areas "Cd" of the
force sensor 100.
As shown in FIG. 4C, the distal surface 102b of the substrate 102
also defines a sensing area "S" onto which sensing element "Se"
(shown in phantom), e.g., strain gauges, are secured. The sensing
elements "Se" may be distributed on the distal surface 102b and
connected in a variety of configurations, as it within the purview
of those skilled in the art.
With reference now to FIG. 5, the distal surface 102b of the
substrate 102 is a generally planar surface having a plurality of
grooves 110 defined therein. The plurality of grooves 110 provide
an area of separation between the distal load contact area "Cd" and
the sensing area "S" of the distal surface 102b of the substrate
102. The plurality of grooves 110 may be micro-trenches, relief
cuts, among other depressed interruptions formed in the distal
surface 102b.
The plurality of grooves 110 may have any width, depth, and/or
shape that interrupts the distal surface 102b of the substrate 102.
In embodiments, the plurality of grooves 110 have a width of about
0.01 mm and a depth of about 0.01 mm. Moreover, while the plurality
of grooves 110 are shown having a rectangular cross-sectional
shape, it should be understood that the shape of the plurality of
grooves 110 may also vary, e.g., the plurality of grooves 110 may
assume a triangular, arcuate, polygonal, uniform, non-uniform,
and/or tapered shape. The plurality of grooves 110 may have any
size and geometry that interrupts the distal surface 102b of the
substrate 102 to allow, for example, a coating to be masked, cut,
or to break without affecting the sensing area "S" of the substrate
102. In embodiments, the plurality of grooves 110 define score
lines, tape lines, or break lines in the distal surface 102b of the
substrate 102 for coating(s).
The sensing area "S" of the distal surface 102b of the substrate
102 is a flat continuous surface, and the sensing elements "Se"
(FIG. 4C) are placed in large strain regions of flex in the sensing
area "S." The sensing area "S" of the substrate 102 is free of
direct contact with the distal load contacting areas "Cd" via the
plurality of grooves 110 thereby minimizing and/or preventing
damage to the sensing element "Se" (FIG. 4C) and/or associated
components thereof (e.g., layers, coatings, circuitry, solder
connections, etc.) as the sensing elements and/or other associated
components are not subjected to the direct loading at the distal
load contact areas "Cd."
In embodiments in which coatings are utilized to protect the
circuitry and/or solder connections (not shown) disposed on the
sensing area "S" of the substrate 102, the coatings may terminate
at the plurality of grooves 110, without the need for masking
processes, thereby minimizing or preventing tearing of the coatings
in regions near the distal load contact areas "Cd" during loading
of the force sensor 100.
In embodiments in which masking is desired, the plurality of
grooves 110 allow for easier masking of the distal load contact
areas "Cd" during fabrication of the force sensor 100. The
plurality of grooves 110 provide break-away zones in which layers
of the sensing elements and/or coatings thereon are forced to break
thereby maintaining the integrity of the sensing area "S" of the
substrate 102. In embodiments, the plurality of grooves 110
provides a region allowing for easy cutting, e.g., with a knife or
razor, to separate the coating from distal load contact areas
"Cd."
Referring now to FIGS. 6A and 6B, another embodiment of a force
sensor substrate 102' is illustrated. The substrate 102' is similar
to substrate 102 and therefore described with respect to the
differences therebetween.
The force sensor substrate 102' includes a proximal surface 102a
(FIG. 4B) and a distal surface 102b' defining distal load contact
areas "Cd" and a sensing area "S". A groove 110' is formed in the
sensing area "S" to isolate a desired solder contact surface in the
sensing area "S" to create a localized region of reduced strain.
The groove 110' includes a series of connected parallel cuts 111,
each cut having a peninsula-like configuration. It should be
understood, however, that one or more grooves 110' may be formed in
a variety of arrangement, e.g., different shapes, depths, and/or
widths, to transfer the strain beneath the distal surface 102b' of
the substrate 102'.
As shown in FIGS. 7A and 7B, the geometry of the groove 110'
corresponds to an end 120a of a flex cable 120, thereby reducing
the strain, under load, at the surface of solder joints (not shown)
formed between the end 120a of the flex cable 120 and the solder
contact surface in the groove 110'. With the reduction of strain at
distal surface 102b' of the substrate 102', the integrity of the
solder connections are enhanced.
While several embodiments of the disclosure have been shown in the
drawings, it is not intended that the disclosure be limited
thereto, as it is intended that the disclosure be as broad in scope
as the art will allow and that the specification be read likewise.
Any combination of the above embodiments is also envisioned and is
within the scope of the appended claims. Therefore, the above
description should not be construed as limiting, but merely as
exemplifications of particular embodiments. Those skilled in the
art will envision other modifications within the scope of the
claims appended hereto.
* * * * *